Title of Invention: Variable Focus Adhesive Additive Spectacle Lens System

Inventors: Don Kreiss; Los Angeles, California, Annie Kerman, Brooklyn, New York

Abstract:

A gel or liquid filled micro or macro multi-layered embossed, adhesive decal lens apparatus. Using high

speed web-rotary embossing technology or other shaping method the present invention simplifies the

manufacturing of magnifying or corrective lenses. In a novel embodiment of the present invention a

high impact polycarbonate roll is embossed with macro or micro circular concave or convex indentations

that can be fixed at differing spherical controlled distortions. This is possible due to the thin film cross

section of the plastic based substrates employed. The novel invention is constructed via multi-layering

of variously shaped components that when assembled work in tandem in the same manner as other one

or multiple piece lenses of prior art. Yet the instant invention provides larger surface areas to be

viewable to the user while creating a plethora of manufacturing efficiencies disclosed herein. An

intermediate gel or liquid layer is sandwiched between a plano, magnifying or corrective similarly

embossed flexible plastic substrate and the embossed macro or micro lens creating one fixed lens unit

or apparatus. This apparatus can be finely adjusted for optical power settings by the end user from the

amount of gel or liquid or type of gel or liquid used to change the refractive properties of the overall

apparatus. Using the refractive index of various liquids, plastics and other transparent materials,

adhesive lenses can be designed to provide the full spectrum of corrective or magnifying lenses. This

apparatus is then lined with non-refractive adhesive that culminates in a decal with either magnifying or

refraction corrective properties to measured spherocylindrical (corrective or magnifying) prescription

values. Through the use of high speed web-die cutting technology each decal lens can be shaped to any

currently available eyeglass design. The current invention also provides the ability to hand cut the lens

to any desired shape thereby uniquely providing infinite customization opportunities. In a further

embodiment of the invention an array of micro embossed lenses are provided to create adjustable liquid

filled spectacles that can be designed in any shape or size. This embodiment solves the issues related to

prior art limitations requiring circular eyeglass designs for adjustable focus spectacles. In a further

embodiment corrective or magnifying decals are adhered to existing corrective or magnifying spectacles

to provide additional use of existing spectacles even though the wearer’s vision has degraded beyond

the ability of the spectacles to correct. This adhesive lens apparatus makes use of the thickness provided

by the existing spectacle and uses formulas derived from U.S. Pat. 3,507,565 to Alvarez and U.S. Pat.

7,325,922 to Spivey. It further employs techniques derived from U.S. Pat. 6,040,947 to Kurtin and U.S.

Pat. 6,930,818 to Rong-Chang Liang and others.

Field of the invention:

The present invention is directed to eyeglasses, reading glasses or sunglasses. The instant invention

provides corrective focus and/or magnifying properties to plano lenses of any shape or type. In a further

embodiment the instant invention can correct degradation of focus in existing patient eyewear without

the need to replace said. Using adhesive or other bonding techniques a plano lens can be transformed

into a corrective or magnifying lens through the use of the present invention. Additionally existing

corrective or magnifying lenses can be transformed into different optical power lenses simply by

adhering the invention to the front or back or both faces of the existing spectacle lenses. Specifically, the

present invention provides a high speed method of manufacturing low cost magnifying and corrective

lenses. In a further embodiment of the instant invention the limitations provided by U.S. Pat. 6,040,947

and U.S. Pat. 5,138.494 as well as other such patented variable focus lenses, wherein circular eyeglass

frames and lenses are required for proper membrane controlled (bulge) distortion are solved by the

present invention.

Background of the invention:

Eyesight is currently enhanced by a number of refraction corrective techniques. Heretofore eyeglass

lenses are primarily made via plastic injection molding of impact resistant polycarbonate materials of

various thicknesses. The final shape and refractive corrective properties of the end product is finalized

through laborious fine grinding techniques that are conducted in specialized laboratories by highly

trained specialists. Lens blanks of varying optical power shaped through the plastic injection molding

process are provided to these laboratories that approximate the oculus dexter and oculous sinister

spherical equivalent power of a lens prescription. Since each human requires a slightly different

corrective solution, lens blanks are fixed at various common spherical equivalent power values

predetermined by the lens manufacturer and chosen by analyzing consumer commonalities derived

from years of patient eyewear needs. These values are set within the industry based on historical data

derived by optometrists and ophthalmologists providing prescriptions and requests for lenses. These

fixed value settings are then used to create molds of fixed spherical equivalent power for plastic

injection molding. The blanks derived using this manufacturing method are then provided for final

grinding processes to eyeglass resellers and lens grinding businesses. The instant invention provides a

method to create optical lenses featuring a range of -6 to + 6 diopter an optical spherical equivalent

power of +4 diopter can be designed while still maintaining a thin lens profile. The adhesive lens decal

apparatus can be made to permanent or repositionable standards.

A typical lens finalization process, after the plastic injection molding phase creates the blanks, is

described below. The following procedure assumes the plastic lenses are being made at an

optical laboratory.

Step 1: The optical laboratory technician inputs the optical prescription for a pair of plastic lenses in the laboratory's computer. The computer then provides a printout specifying more information necessary for producing the required prescription.

Step 2: Based on this information, the technician selects the appropriate plastic lens blanks. Each blank is placed in a prescription tray along with the customer's eyeglass frames and the

original work order. The prescription tray will remain with the technician throughout the production process.

Although the appropriate curves have already been ground into the front of the lens, the

technician must still grind curves into the back of the lens. This is done in a curve generator.

After polishing the lenses, they are put in an edge grinder, which grinds each lens to its proper

shape and places a bevel around the edge so that the lens will fit the eyeglass frames. Following

any necessary tint applications, the lenses are put into the frames.

(A1)The plastic blanks have different curves already ground into the front of them;

therefore, the technician must select the blank that corresponds to the optical

prescription required for each lens. The rest of the optical prescription, or power,

must be ground into the back of the lens.

Blocking

(A2)The technician places the lenses in a lensometer, an instrument used to locate and mark the "optical center"—the point that should be centered over the customer's pupil—of the lens blanks. Next, adhesive tape is affixed to the front of each blank to keep the front from being scratched during the "blocking" process. The technician then places one lens blank at a time in a "blocker" machine, which contains a heated lead alloy that fuses the block to the front of the blank. The blocks are used to hold each lens in place during the grinding and polishing processes.

(A3)Next, the technician places each blank into a generator, a grinding machine that is set for the optical prescription. The generator grinds the appropriate optical curves into the back of each lens. After this step, the lenses must be "fined," or polished.

(A4)The technician selects a metal lens lap —a mold corresponding to the required

optical prescription of the lens, and both lenses are placed in the fining machine with the

back of each lens in the appropriate lap. The front of each lens is then polished in a series

of fining operations. First, each lens is rubbed against an abrasive fining pad made of soft

sandpaper. After a second fining pad made of a smooth plastic is placed over the original

sandpaper pad, the lens is polished again, as the fining machine rotates the pads in a

circular motion while water flows over the lenses. After the initial fining process is

completed, the two pads are peeled off and thrown away.

Next, the laps are removed from each lens and soaked in hot water for a few moments.

The laps are then attached back on the lenses and placed in the fining machine, where the

third and final fining pad is attached. The fining machine rotates the pads in a circular

motion while a polishing compound consisting of aluminum oxide, water, and polymers

flows over the lenses.

The lenses are removed from the fining machine, and the block attached to each lens is

gently detached with a small hammer. Then, the tape is removed from each lens by hand.

The laps are sterilized before they are used to hold other lenses.

(A5)Each lens is marked "L" or "R" with a red grease pencil, indicating which is the left

and right lens. After the lenses are again placed in the lensometer to check and mark the

optical center and inspect the other curves necessary for the proper optical prescription, a

leap pad —a small, round metal holder—is then affixed to the back of each lens.

Beveling

(A6)Next, the technician selects the lens pattern that matches the shape of the eyeglass

frames and inserts the pattern and the lenses into an edging machine. The machine grinds

each lens to its proper shape and places a bevel around the edge of the lens so that the

lens will fit the eyeglass frames. Water flows over the lens throughout this process.

If the lenses require additional grinding, the process is done by hand using a mounted

power grinder. This step is necessary for lenses to be inserted in metal or rimless frames,

which require more precise bevels.

Finally, the lenses are dipped into the desired treatment or tint container. After drying, the

eyeglass lenses are ready for insertion in the desired frames. The optical laboratory may

send the lenses back to the optical outlet without the frames, in which case the optical

outlet will insert the lenses in the frames.

As people get older generally around age forty five the lens in the human eye becomes

incapable of sufficient accommodation to focus on near objects. This condition is called

presbyopia.

(A7)The continued degradation of vision as human’s age requires the use of multiple

corrective glasses that can usually add about three diopters to the optical power of the

eyeglasses or contact lenses used. This can become an expensive investment in multiple pairs of glasses with older glasses simply becoming obsolete. The cost of making a lens

to a prescription value obtained from an optometrist or ophthalmologist can become

prohibitive to older retired individual or individuals from third world countries. The

process of plastic injection molding of lens blanks that are then further processed as

aforementioned is time consuming and requires multiple steps that are usually undertaken

by laboratories that supply eyeglass frame retailers. In U.S. Pat. No. 5,138,494, issued to

Stephen Kurtin and in U.S. Pat. No. 6,040,947, also issued to Stephen Kurtin a variable

focus liquid filled spectacle lens is also described that is purported to solve some of the

cost constraints that are associated with lens manufacturing. The issues surrounding the

use of variable focus lenses at first glance seem appealing in that they can be customized

to the individual focus required by the user at the time of use. For reading one focal

setting can be obtained by adjusting the amount of fluid pressure within a lens chamber

created with two separate substrates surrounding a flexible membrane. Many patents

address this category of liquid filled variable focus lenses. But even in this form of lens

the substrate that comprises the actual outward part of the “lens” sandwich is still plastic

injection molded and then assembled into a lens unit. And much of the manufacturing

cost is transferred to the frame mechanism construction and overall spectacle assembly

process. A typical manufacturer of high end eyeglass wear using the described method is

retailing for twelve hundred dollars.

(A8)(See Aldens corrective prescription model)

In these types of liquid filled variable focus lenses, circular lens construction is essential

to avoid optical distortion. If the lenses are made to style considerations then issues arise

as the plethora of eyeglass frames in current use worldwide is too numerous to

accommodate only circular lenses.

The present invention addresses prior art limitations in a series of novel methods that use

currently existing embossing and other material shaping technology to replace the need

for plastic injection molding of the rigid lens blanks combined with novel methods that

reduce the cost and number of steps required to create corrective and magnifying glasses.

In a further embodiment of the present invention the use of microcups currently in use in

electrophoretic displays are specifically designed to solve the limitations associated with

liquid filled circular variable focus lenses. The present invention and further objects will

become evident to those skilled in the art after reading the following specification

together with the attached drawings.

Summary of the invention:

Using optical formulas of prior art describing the lens thickness and refractive index of

certain materials and liquids the present invention employs an additive and subtractive

multi-layered method to create predetermined refractive apparatus that adhere to plano or

magnifying or corrective preexisting lenses, sunglasses, safety glasses, or other objects

where corrective or magnification of indicia is required.

The first aspect of the invention provides that the shaping of the front or outer face of a

lens can be made to a minimum thickness value and additional refraction needed for the

finished lens can be provided by either addition of layers of shaped materials, gels,

liquids or other substrates whether liquid or solid. By limiting the thickness required for

the front or outer face of the lens apparatus many material shaping methods can be

employed to accurately provide transparent substrates the curvature required to create

optical spherocylindrical (corrective or magnifying) prescription values in said substrate without the need of plastic injection molding processes or grinding and other such finishing processes previously described.

In one aspect of the invention the formulas of U.S. Patent 7,325,922 B2 to Spivey which

refers to U.S. Patent 3,507,565 to Alvarez with concerns of the lens thickness profiles

developed for a multi-lens variable focus spectacle apparatus.

The basic general equations defining the thickness profiles are given by:

( ( av+ 1 )-2

a3t/au

3 +a( av+ 1 )

-1a

2t/avau) l(u,vF(o,o)~2A

( d3t/av

2au )l(u,v)~(O,O) ~2A

( ( av+ 1 )-1

a3t/avau

2-a( av+ 1)

-2d

2t/du

2) l(u,v)~(o,o)=0

. The notation "(u,v)=(O,O)" indicates that the relations only hold for the center point

(u,v)=(O,O), but not necessarily outside of that point. However, prior applicant requires

the thick-ness profile functions to be continuous, and the derivatives up to at least third

order to be continuous. Applicant picks A for one lens to be the complement (negative

value) of A for the other lens.

The solutions to these equations are:

t = A[uv2 + 2(av + 1)(au-sin(au))/ a3] + B[2(av + 1)(1-cos(au)) I a

2)] + C[vsin(au)/ a-(au-

sin(au)) / a2)] + Du + E + F(v) + F1(u, v)u

4 + F2(v)u

3v + F3(v)u

2v

2 + F4(v)uv

3,

where

F(v), F1(u,v), F2(v), F3(v), F4(v)

are any functions over the area of the lenses for which derivatives up to at least third

order are continuous.

Translation Only Designs:

In the case of translation only designs, a=O. Prior Applicant has defined x=u, and y=v.

He defines the origin x=O, y=O to be the point directly in front of the pupil when looking

straight ahead. The equations in this form for the translation designs are:

(d3t/dx

3)1(x,y)=(0,0)+2A,

(d3t/dxdy

2)1(x,y)=(0,0)=2A, and

(d3t/dx

2dy)1(x,y)=(0,0)=0

Note that the Alvarez description referred to in the Back-ground Section is the same at

the center (x,y)=(O,O), but Alvarez also applies this restriction away from the center

point whereas the present invention considers a wide variety of parameters to optimize

the design across the entire lens profile. As above prior Applicant picks A for one lens to

be the complement of A for the other lens.

The solution is found by taking the limit as a~o in the above thickness expression, which

results in.

t=A(xy2+1/3X

3)+Bx

2+Cxy+Dx+E+F(y)+F1(x,y)x

4+F2 (y)x

3y+F3(y)x

2y

2+F4(y) xy

3

This can be seen as identical to the Alvarez except for the addition of F1, F2, F3 and F4.

These additional functions will be shown in this patent to be important for optimized

performance. Designs including rotation: The relative motion perpendicular to the

viewing direction may also include rotation in the plane of the lens. In this case, at least

one of the lenses pivots about a pivot location. For a good solution to exist, this must be

outside of the lens perimeter.

For the pivot design, we will call r00=u, and r-r0=v, with r0=1/a. The origin r=O is the

pivot point, and r=r0, 8=0 is the point directly in front of the pupil when looking straight

ahead. In this form, the equations are given by

r 0 -1

(r-2

a3t/a0

3 +r

-1a

2t/ara0)1(r,0)(r0,0)=2A

r 0 -1

(a3t/ar

2a0)|(r

-2a

2t/a0

2)|(r,0)=(r0,0)=0

The solution in this form is

t=Ar0[(r2+r0

2)0-2rr0 sin(0)]+B2r0r(1-cos(0))+Cr0[r sin(0)-r00 }+Dr00+E+F(r)+Fl (r,0)r0

40

4 +F2(r) r 0

3 (r-r 0)0

3 +F3 (r)r 0 (r-r 0) 0 +F 4(r )r 0(r-r 0)

30,

The terms have been defined so that the constants are the same as in the general equation,

but a shorter equivalent form provided below is possible by redefining the constants:

t~A'r20+B'r cos(0)+C'r sin(0)+D'0+E'+F'(r)+F1'(r,0) 0

4+F2'(r)(r-r0)0

3+F3'(r)(r-

r0)20

2+F4'(r) (r-r0)

30.

Choosing Parameters

The choice of parameters to the general solutions depends on desired optical

performance, other restrictions such as minimum and maximum thickness and aesthetic

and other considerations. These specific optimum solutions use a form much more

general than that described by Alvarez. Prior Applicant picks the parameters and

functions to optimize lens properties. In preferred embodiments specific parameters and

functions are optimized to provide desired performance and other quality and aesthetic

results.

In the instant invention the thickness parameters of the lens apparatus constructed by the

novel method envisioned herein are determined in a three part manner for the first

embodiment. Both the formula described by Alvarez and further developed in U.S. Pat.

7,325,922 can be the foundation of the new formula required to incorporate the added

fluid refraction and volume used to create the optical focal power.

By adding volumetric function represented by an ellipsoid in the volume formula for

v= (4/3) pi r1 r2 r3

And having a surface area equal to

2 × π × [c² + (b × c²)/(√(a²-c²)) × F(ᵩ,k) + b × √(a²-c²) × E(ᵩ,k)]

And then a refractive index of the fluid used of

n=c/v,

Wherein n represents the type of fluid used.

Using the fundamental elements of variable focus lens described in U.S. Pat. 6,040,947

wherein a flexible membrane is made to distort to required curvature within a fluid with a

front or outer curved lens and combining them with the novel methods described in U.S.

Pat. 7,325,922 describing two or more lens working in tandem to create an optical axis

that can be adjusted through the positioning of disparate lens surfaces that complement

each other. The instant invention combines the best practices of both forms of variable

focus spectacles into one method that allows for novel and improved efficiencies not

realized by prior art.

Through the use of embossing and other thin film shaping techniques front and rear lens

surfaces can be shaped into partial refractive index portions of an overall apparatus that

continues to provide a thin edge profile that is stylish and flexible, yet continues to

exhibit the impact and scratch resistance inherent in poly-carbonate lenses currently in

wide use for spectacle manufacturing.

A multi-layered spectacle lens can be constructed by this novel method that allows for

adhesive decal-like lens additive thin film sub-lenses to be assembled in unique and

optical power preset layers that when combined become one lens of a differing optical

power. Multiple layers of different focal refractive design will combine together to create

the full spectrum of -6 diopters to +6 diopters optical power values and every possible

lens focal optical power value in between. Whether a membrane is made to distort within

a fluid or two lenses are either rotated or slid across each other to create the desired

optical power lens configuration prior art is limited due to cost of creating the lens out of

substrates that provide the refractive properties desired while maintaining the impact and

scratch resistance eyewear currently provide users.

Using the novel method described in this instant disclosure eyewear can be retained for

use even after the focal optical power is not sufficient to provide the necessary ability for

the user to see properly. This is accomplished because the decal lens made using the

novel methods disclosed allow a user to simply press or attach a decal to the existing

eyeglass of any optical power setting and thereby modify the optical power of the

preexisting lens with the appropriate additive decal lens.

By adding sequentially varied optical power sub lenses one atop the other by adhering

them together the final lens apparatus of this disclosure will allow used lenses that no

longer have the optical power corrective or magnifying properties needed by the wearer

to be reconditioned to a new and appropriately suitable optical power value.

Variable focus spectacles of prior art attempt to provide the wearer the ability to vary

focal optical power through a wide range of diopter values. Usually from -4 diopter to +4

diopter focal optical power by the turning of a knob or other mechanical device that

distorts a floating flexible membrane within a fluid in one iteration or by moving the

position of two or more lenses in relation to each other. Both methods are expensive to

manufacture and are unsightly and non-stylish to wear.

This is why neither method has actually been adopted by the general spectacle wearer. It

is one of the objects of this invention to provide the spectacle wearer a new more stylish

alternative to variable focus lenses while still providing the efficiencies and lens quality

that currently exists in the marketplace.

In one embodiment of the invention fixed focal optical power lenses would be embossed

into the polycarbonate substrate currently in use for spectacle lens eyewear. The thinner

profile of the lenses designed in the instant invention are possible due to the novel multi-

layered method incorporated in this embodiment. The front face of a plano or magnifying

or corrective polycarbonate lens embedded in the eyeglass frame is used as the equivalent

thickness evident in current lenses. The front face decal and the rear face decal of this

instant invention can therefore be made extremely thin due to the additive nature of the

three or more layers that comprise the full lens apparatus. Rather than creating one full

dimensional apparatus that contains the required thickness of substrate needed to create

the refractive index values that will provide the corrective or magnifying optical power of

the spectacle desired, a base lens serves as a platform that will provide the flexibility to

create any needed optical power lens by simply applying decals to the front, back or both

sides of the base lens.

By creating a system of pre-designed lens blanks of base magnification or corrective

optical power values and then creating additive lens decals the entire breadth of needed

optical power spectacles can be designed as either an originating lens creation system that

replaces and competes favorably with current lens creation techniques or as an

aftermarket method to enhance sunglasses, older spectacles or any eyewear that needs

enhanced optical power values.

Brief description of the drawings:

FIG. 1 (2) is a top view of an embossing roller plate featuring pre-designed concave or

convex or both elements. (5) Shows the final lens indentation in a thin film polycarbonate

transparent sheet or roll. (1) Shows a side view of the final lens surface.

FIG. 2 (1)(2) show a side view of a front and rear lens sheet of the embossed

polycarbonate sheet lens array of FIG. 1. (5) show a side view of a thick base lens, fluid

filled lens or other refractive element used to provide the platform needed for the final

optical power values of the apparatus.

FIG. 3 (1)(2)(3) show a side view of the embossed lens array of FIG. 1 with the added

eyeglass drawing that displays the lens shaped to fit in eyeglass frame upon embossing.

FIG. 4 (1)(2)(3)(4) show a sub-lens assembly front face and rear face embossed lens

decal. (5) show a small decal lens used as a bi-focal or magnifying apparatus as applied

to (2) eyeglass base lens apparatus.

FIG. 5 (1)(3)(4)(5) show a double lens apparatus that is attached to a base lens apparatus

or sunglasses or other eyewear to either create a magnifying or corrective bi-focal like

lens decal system with detachable positioning member.

FIG. 6 (1)(3)(7)(11)(15) show a side view of various thin layer iterations of the lens

curvatures disclosed in U.S. Pat. 3,507,565. The present invention provides for thinner

lens profiles with base lenses providing the required additional refraction thickness

through additive build-up of varied lens configurations that comprise the final combined

refractive properties of the lens apparatus disclosed herein.

FIG. 8 (10)(1)(7)(8) show a side view of a lens apparatus designed using the techniques

disclosed by U.S. Pat. 3,507,565 with the novel thin film additive decal system of the

instant invention. (5) shows the base lens, fluid filled base, and/or the existing

corrective/sunglass/magnifying existing lens that requires enhancement.

FIG. 9 (1)(3)(10)(9)(11)(6)(7)(8) shows the corrective or magnifying lens disclosed in

U.S. Pat. 6,040,947 as embodied in the present invention. The flexible membrane is

positioned in a fixed state and then a decal is created that is larger than the eyewear base

lens. Then a front facing sub-lens apparatus and a rear face sub-lens apparatus is attached

to a base lens apparatus wherein the combined refractive indexes of all three units create

one optical focal value. This embodiment provides a thinner eyewear profile and allows

for re-application of differing optical power values as the wearer’s eyesight degrades.

FIG. 10 (9)(8)(13)(10)(16)(11) Show sub-lens decal assemblies as they would interlay

with the base (14)(2) lens of an eyeglass or spectacle frame.

Detailed disclosure of preferred embodiments:

In one embodiment of the present invention adhesive decal FIG. 4 (5), FIG.5 (7)(3)(4) is

created to provide sunglasses or other corrective or magnifying eyewear lenses the ability

to enhance the optical power values of a specific area generally in the lower quadrant of

the eyeglass or spectacle eyewear. This embodiment addresses a specific need in the

marketplace wherein current solutions for reading glasses used by persons needing

additional magnification if indicia is of smaller text point values. Individuals currently

are required to either have a separate additional spectacle or use bifocal glasses or other

unwieldly solution.

In FIG. 4 a small sub lens decal with magnification properties ranging in optical power

values from +.5 to +8 can be achieved while still maintaining the thin profile many

eyewear users prefer. In this embodiment the base lens (2) is additive to (5) and (3). Each

decal sub lens adds optical power to the overall lens apparatus.

As shown in FIG. 5 drawings further establish that a two part sub-lens decal (1) is

designed to the disclosures contained herein and then combined with the base plano or

corrective or magnifying lens (2). In this iteration of the present invention reading glasses

can have enhanced optical power decals applied to lower quadrants of the lens providing

a second magnifying optical power element to the established existing eyewear lens

(2)(6). Sunglasses can be converted to reading glasses by adding the sub-lens decal

apparatus using the additive process of the present invention to create the desired optical

power values (4). A simple connective tear-away substrate (5) can be used to position the

decal sub-lenses (4) onto the base eyewear corrective, magnifying or plano lens (2)(6)

already encased in the eyewear frame. In a preferred embodiment the eyewear will have a

fluid filled (6) base lens middle portion and that fluid will have a controlled refractive

index that when combined with the sub-lens apparatus (2) will result in the desired

optical power values sought for the overall eyewear finished lenses.